Lean manufacturing principles originated to reduce waste and improve process flow in production environments. Initially developed in the automotive sector, it has since been applied across multiple industries seeking greater operational control. By focusing on minimizing non-value-added activities, lean principles help organizations stay agile, reduce cycle times, and optimize resource allocation.
However, integrating lean initiatives with workplace safety measures presents opportunities and challenges. In highly regulated industries—particularly in Ontario—manufacturers must also comply with requirements such as Pre-Start Health and Safety Reviews (PHSRs) under Ontario Regulation 851.
At first glance, these two concepts might seem at odds. However, when applied strategically, PHSRs and lean methodologies can work together to reduce risks and reinforce compliance while strengthening operational flow.
How PHSRs Complement Lean Initiatives
PHSRs are engineering evaluations required before specific machinery, processes, or structural modifications are introduced into a workplace. They are mandatory under Ontario’s Occupational Health and Safety Act (OHSA) and apply to new or modified apparatus that could affect worker safety.
While lean systems aim to eliminate waste, they depend on predictability and standardized procedures. This is where PHSRs provide measurable value. By identifying potential safety issues before equipment is operational, a PHSR allows manufacturers to address hazards proactively. The result is a safer environment that aligns with lean goals—less downtime, fewer disruptions, and more predictable workflows.
For example, a manufacturer redesigns a production cell to reduce walking distances and movement waste. The redesign includes relocating a robotic arm. Due to the change in guarding and motion range, a PHSR is triggered. By completing the safety review before start-up, the team avoids costly mid-process changes, keeps timelines intact, and maintains alignment with lean objectives.
Case Study: Quebec Aeronautics Shows the Strength of Integrated Safety
In the Quebec aeronautics sector, a detailed study published on ResearchGate highlights how embedding occupational health and safety principles into lean manufacturing processes can produce tangible operational gains.
Participants in the study noted that involving health and safety professionals early in lean projects helped identify hazards before changes were implemented. This approach reduced workplace incidents and supported lean goals by eliminating unplanned delays and minimizing waste caused by rework or injury-related shutdowns.
The research challenges a common misconception that safety and lean exist in tension. Instead, it demonstrates that when planned collaboratively, safety interventions can stabilize workflows and contribute to a more consistent, hazard-aware production environment. This alignment is even more relevant for organizations in Ontario, where PHSRs are a legal requirement under specific conditions.
The research very well positions a PHSR report in engineering as a compliance requirement and a deliberate step toward creating safer, and more consistent operations. The paper, titled Integration of Occupational Health and Safety into Lean Manufacturing: Quebec Aeronautics Case Study, examined infrastructures and revealed that integrating safety did not compromise lean outcomes—it reinforced them.
Conclusion: Achieving Operational Excellence Through Integrated Approaches
Rather than viewing compliance as a barrier, manufacturers can treat PHSRs as strategic checkpoints that align with lean values. Conducting these reviews early in the process gives engineering and production teams the foresight needed to adjust plans before problems emerge. The outcome is a production environment that is safer, more stable, and better aligned with operational goals.
SAFE Engineering Inc. supports manufacturers in aligning modern lean practices with Ontario’s safety obligations. Contact the team today for an extensive understanding of integrating lean principles and PHSRs.
